Although the automotive trade was one of many earliest adopters of additive manufacturing (AM) for prototyping functions, the price of the know-how has been too excessive to use it to finish half manufacturing at scale. That’s starting to vary, nevertheless, and one of many leaders demonstrating the paradigm shift happening is the Volkswagen Group (VW), which has been steadily rising its steel 3D printing capability. The most recent transfer from VW is the acquisition of a second MetalFAB 3D printer from Dutch producer Additive Industries.

VW Provides Second MetalFAB 3D Printer

Volkswagen started ramping up its use of steel AM in 2018, when it established a 3D printing middle devoted to the know-how. There, the automotive big put in a MetalFAB laser powder mattress fusion (LPBF) machine, which it selected for its excessive stage of automation, thus lowering guide intervention and bettering security. Furthermore, the 3D printer is modular in design, permitting VW to increase manufacturing capability with out essentially investing in fully new machines.

This 3D printed tooling nozzle is used for the manufacturing of the VW Tiguan, with over 1,000 made per 12 months for the manufacturing of the car. Beforehand, the aspect was made up of two machined and welded elements. With the MetalFAB system, there isn’t a post-processing required, leading to 650 % value discount.

Additive Industries highlights the improved throughput potential with its programs, together with full-field lasers and automatic construct changeovers. VW has moreover engaged in parameter growth with the corporate, in addition to invested in its Powder Load Device and Powder Restoration Station.

The nozzles produced as a batch inside the MetalFAB machine.

“We as Additive Industries are happy to have the ability to present Volkswagen Group with their second MetalFAB system. We’re right here to assist them increase their capabilities within the discipline of additive manufacturing and transfer in the direction of the following step within the automotive trade,” mentioned Mark Massey, Chief Govt Officer at Additive Industries.

3D Printing in Automotive

A lot of developments have seen the automotive sector embrace 3D printing for finish elements at an rising charge. Amongst these is the evolution of processes for bigger batch manufacturing, in addition to additional automation. The previous mainly pertains to bigger steel 3D printers and the expansion in steel binder jetting. LPBF programs are increasing by way of construct quantity and laser capability, permitting for greater throughput, thus permitting these printers to pay for themselves extra shortly. In the meantime, steel binder jetting is being pitched as a cost-competitive course of for 3D printing bigger numbers of elements.

So far as automation is anxious, 3D printer producers and customers are trying to scale back the full quantity of human intervention required to run machines. BMW, as an illustration, was concerned in a key venture devoted to automating the pre- and post-process steps in LPBF. Since then, BMW has begun the same course of with sand casting cores.

Based in 2012, Additive Industries was among the many first 3D printer producers to concentrate on automation, when it unveiled the primary iteration of its MetalFab system. Whereas different companies started to toy with the concept, Additive Industries basically pushed the LPBF sector as a complete to discover automation in earnest.

With this in thoughts, the MetalFAB is an apt selection for VW, which is Europe’s largest carmaker and operates 12 manufacturers, together with Audi, Porsche, Ducati, Bentley, and Lamborghini. Via all of those manufacturers, VW firm is a significant person of AM and has set excessive targets for using the know-how in finish half manufacturing. With HP’s steel binder jet know-how, as an illustration, it goals to 3D print 100,000 elements yearly.

Additive Industries’ Trajectory

Regardless of its high-end programs and high-profile purchasers, Additive Industries struggled a bit because the trade and financial system as a complete slumped. In flip, the Wintermans household, the agency’s main investor that helped co-found Additive Industries, devoted additional funds to the enterprise, as its former CEO transitioned out in 2020 earlier than but one other CEO left in 2022. Massey, the present chief of the corporate beforehand served as chief business officer.

Additive Industries’ general technique, to extend throughput and high quality management so as to cut back complete value of possession over time, is a stable one. Furthermore, it has the help of a loyal investor within the Wintermans household, who ought to proceed to again the agency because it progresses. Even within the tumult of government modifications, is has been capable of finding new and keep outdated clients, together with ABB, Safran, and VW.

Repeat enterprise from highly effective clientele would recommend that the corporate and its know-how stay agency and, as Europe reaches for additional decarbonization and provide chain resilience, the Dutch 3D printer producer may discover itself rising fairly shortly.